Wire feed control assembly

ABSTRACT

A wire feed assembly and torch and welding systems are disclosed. The wire feed assembly includes a motor drivingly connected to at least one roll of a pair of rolls. A controller is connected to the motor and is constructed to control the operation thereof. A knob is rotatably connected to the controller and facilitates an operator&#39;s adjustment of the controller. A collar is disposed between knob and the controller and is fixedly connected to the controller and engaged by the knob to resist movement of the knob and thereby adjustment of the controller.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of, and claims priority to, U.S.application Ser. No. 11/148,875, filed Jun. 9, 2005, the disclosure ofwhich is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates generally to welding-type systems and,more particularly, to a welding torch operable with such systems.

Welding-type systems generally include a power source constructed togenerate a welding-type power. The welding-type power is communicated toa torch assembly or a welding gun via a weld cable that extends betweenthe torch and the power source. Some systems include a consumable weldwire that is fed to the torch. The consumable weld wire can be pushed orpulled using a single motor wire feeder, or can be push/pulled by a dualmotor wire feeder having a first motor near the power source and asecond motor nearer to, or supported by the torch. During a weldingprocess, actuation of a trigger of the torch actuates the motor(s)thereby delivering the consumable weld wire from the torch to a weld.

Torches that include a wire feed assembly, commonly referred to as awire feeder, allow for operation of the torch at greater distances froma power source and/or use of consumable weld wires that are incapable ofbeing only pushed to the torch. That is, if the distance between thewire feed assembly and the torch is too great, the wire feed assemblywill not be able to overcome the friction or drag associated withpushing the weld wire to the torch. Additionally, some consumable weldwires cannot support the stresses associated with being pushed and/orpulled from the power source to the torch and must therefore be locatedat the torch and delivered to a weld therefrom. Positioning the wirefeed assembly on the torch also allows for efficient control andoperation of the wire feed assembly. An operator is not required toreturn to the power source to adjust the wire feed assembly.

During a welding process, the consumable weld wire passes between a pairof the rolls of the wire feed assembly. The wire feed assembly includesa motor that operatively engages at least one roll of a pair of rolls.Operation of the motor rotates the roll and thereby moves the consumableweld wire through the torch and to a weld. The rolls are often separableto allow the initial positioning of the consumable weld wiretherebetween. This process is often referred to as “threading” of thewire feed assembly and requires that the rolls be located in a threadingposition. When located in the threading position, the rolls are movedapart to form a gap between the rolls. This gap is generally largeenough to allow the consumable weld wire to move freely between therolls. Once the consumable weld wire is positioned between the pair ofrolls, the rolls are positioned snuggly against the wire, or in a feedposition, such that rotation of the rolls “feeds” the weld wire throughthe wire feed assembly. This threading of the wire feed assembly must berepeated every time a terminal end of the consumable weld wire exits therolls or an operator desires an alternative consumable weld wire.

A cam is often employed to separate the rolls so that the consumableweld wire can be threaded therepast. The cam can engage one roll or bothrolls and, when actuated, forms the separation between the rollsnecessary to pass the consumable weld wire freely therebetween. Thesecams require constant operator actuation to maintain the separatedcondition of the rolls. This requires an operator to maintain handcontact with the cam at all times during the threading process.Additionally, once a threading process has begun, if the consumable weldwire, the spool the consumable weld wire is mounted upon, the weldcable, the power source, or any other component of a welding systemrequires adjustment, the operator only has one hand available to makesuch adjustments while maintaining the rolls in the separated position.Occasionally, during a threading process, the consumable weld wire maybecome stuck in the weld cable which communicates the consumable weldwire to a torch. Freeing of the consumable weld wire often requiresmanipulation of the weld cable to allow the continued passage of theweld wire therethrough. If the operator requires two hands to manipulatethe weld cable to free the consumable weld wire, the threading processmust be suspended until the manipulation of the weld cable is complete.That is, the cam must be released and later re-engaged to continue thethreading process every time a two-handed adjustment of the weldingsystem is required during a threading process. Accordingly, such wirefeed assemblies often require an operator to repeatedly open and closethe rolls of the wire feed assembly during a threading process. As such,manually passing the consumable weld wire through the wire feed assemblycan be a time consuming and frustrating process.

Once the consumable weld wire has been thread to the torch, the weldwire can be delivered automatically therefrom by the wire feed assembly.Occasionally, responsive to arc/weld performance, an operator needs toadjust the rate of delivery, or feed speed, of the consumable weld wire.The wire feed assembly often includes a control connected to the motorof the wire feed assembly to facilitate adjustment of the wire feedspeed. Welding systems that have a wire feed assembly supported on thewelding torch also often have a feed control supported thereon.Positioning the feed control on the torch eliminates an operator'srepeated trips away from a workpiece and/or torch assembly to adjust thewire feed speed. The feed control often includes a knob or dial that isaccessible through a housing or handle of the torch. The knob isconnected to a shaft of the control such that rotation of the knobadjusts the signal output from the control. Although mounting the wirefeed control in the torch is convenient and efficient for operatormanipulation of the control, it is not without its drawbacks.

A control that is supported by the torch is also subject to themovements and impacts subjected to the torch. That is, during a weldingprocess, the torch can be repeatedly subjected to impacts. For example,during welding processes, slag can collect in a nozzle of the torch.Rather than removing the nozzle from the torch to remove the slagtherefrom, some operators tap the torch on a work surface to remove theslag from the nozzle. Occasionally, attempting to ensure that the torchand weld cable are clear of a work area, an operator will manipulate aposition of the torch by manipulation of the weld cable. Understandably,the torch, and any components supported thereon, must be ruggedlyconstructed to withstand these and other rigors associated with aworkplace and weld processes. Not only do the impacts to the torchaffect the operation of the wire feeder attached to the torch, they canalso affect the setting of the feed control connected thereto.

Each impact that the torch is subjected to also imparts a portion ofthese forces on the components of the feed control. Occasionally, theseforces result in inadvertent adjustment of the feed control. In additionto the impact forces the torch is subjected to, the torch is alsorepeatedly gripped and released during a welding process. This repeatedgripping and releasing of the torch can also result in inadvertentadjustment of the feed control. That is, the feed control mayinadvertently and unknowingly experience an adjusting contact with anoperator's cloths or gloves, a workpiece, or other workplaceobstructions such as a workpiece. Accordingly, if an operator does notconfirm the setting of the feed control with each successive gripping ofthe torch, actuation of the trigger of the torch would result inoperation of the wire feed assembly at an undesired feed speed.Attempting to weld at a feed speed that is unknown and/or undesired willresult in poor, if any, weld arc performance.

Maintaining the wire feed speed at a desired value for the duration of awelding process allows for efficient and extended operation of thewelding torch. Accordingly, a single operator of the welding torch canachieve greater efficiency with decreased delay between successive weldprocesses. Such efficiency achieves extended periods of welding systemoperation by an individual operator. As such, operator fatigue must alsobe considered in constructing such torches. The weight, ergonomicimpact, and operating temperature of the torch are only three of manyconsiderations that must be addressed in constructing a torch that canbe operated for extended periods by a single operator. Torches are oftenoperated by a single hand of an operator thereby allowing for workpiecemanipulation by the operator's free hand. The torch must be constructedto comfortably fit in a grip of an operator. This requirement oftenrequires miniaturization of internal components of the torch and ahandle assembly that can support the heat and power requirementsassociated with extended operating periods. Often times, the conductorsthat communicate the welding power through the torch include severalindividual conductors that extend along the length of the torch handle.Multiple conductors allow the torch to accommodate other components,such as a trigger assembly and/or a wire feed assembly, whilemaintaining a single hand graspable torch. Additionally, partitioningthe weld power across several conductors reduces the amount of heatgenerated by each individual conductor as compared to a torch requiredto communicate the same weld power through the torch over fewerconductors. However, diversifying the weld power across the severalconductors does not decrease the total amount of heat generated in thetorch assembly by the communication of the weld power therethrough.

In addition to the weld power, a weld gas is also communicated throughthe torch assembly to a weld. The weld gas is often directed through oneof the weld power conductors rather than providing a dedicated conduitfor the weld gas. Passing the weld gas through a single conductorprovides an adequate flow of weld gas to a weld process and providessome degree of cooling of the torch assembly. However, temperature ofthe torch assembly is an issue when the torch is operated for extendeddurations and at increased weld powers. That is, the passage of weld gasthrough a single conductor of the torch assembly limits the amount ofweld power and the duration of weld intervals that a torch can provide.Other torches utilize a water cooling loop that circulates a fluidcooling flow the conductors of the torch. Such torches can operate athigher weld powers as compared to torches having weld gas coolingsystems but are difficult to maintain and more expensive to manufactureand operate. Such torches must be fluidly connected to a reservoir andpump to circulate the cooling fluid therethrough. Additionally, suchtorches require that at least two of the conductors be fluidly connectedwithin the torch to form a circulation loop for the cooling flow.Accordingly, these torches require complex assembly and precisionmanufacture to ensure that the fluid loop is isolated from the othercomponents of the torch.

In addition to the heat generated by the communication of the weld powerthrough the handle of the torch, the portion of the torch that extendsbeyond the handle portion, or the barrel assembly, is also susceptibleto thermal accumulation. A nozzle is positioned at a distal end of thetorch assembly and is positioned in very close proximity to a weldduring a welding process. The barrel assembly is generally disposedbetween the nozzle and the handle portion of the torch. As theconsumable weld wire is discharged from the handle portion of the torch,the barrel assembly directs the consumable weld wire and the weld gasdelivered from the torch assembly to a weld. The close proximity of thebarrel assembly to the weld process exposes the barrel assembly to theconsiderable thermal energy associated with a weld process. That is, thebarrel assembly experiences convection and radiation heating due to itsproximity to a welding operation.

In addition to the convection and radiation heating of the barrelassembly, a portion of the heat communicated to the barrel assembly isconducted through internal components of the barrel assembly. Aplurality of tubes is internal to the barrel assembly and isolates thecommunication of the consumable weld wire, weld power, and weld gas to aweld. As the weld wire is consumed during a welding process, heat isconducted along the length of the weld wire into the barrel assembly.Some of this heat is transferred to the plurality of tubes and therefromto an exterior surface of the barrel assembly. Similarly, the nozzle ofthe torch assembly is supported by the barrel assembly and located inclose proximity to the weld pool during a welding process. As such, heatcollected in the nozzle is also conducted to the barrel assembly.

The length of the nozzle and barrel assembly, in addition to the gapbetween the torch and the workpiece, is often all that determines thedistance of an operator's hand from the weld pool. That is, a trigger ofthe torch is often mounted on the torch assembly in relatively closeproximity to the barrel assembly. As such, an operator is often exposedto the heat that is accumulated in the barrel assembly of the torch.Even located in a heavy glove, an operator's hand can still perceive andbe subjected to the heat of the barrel assembly of the torch.Occasionally, after extended periods of torch operation, theaccumulation of heat in the barrel assembly can result in an operator'sinability or unwillingness to operate the torch, or if unaddressed,result in damage to the barrel or the torch assemblies.

It would therefore be desirable to provide a torch assembly that has awire feed assembly having a pair of rolls securable in a positionnecessary to pass a consumable weld wire freely between. It wouldfurther be desirable to provide a feed control for the wire feedassembly that is resistant to inadvertent adjustment of the control. Italso would be desirable to have a torch assembly having a plurality ofweld gas passages formed therethrough. Additionally, it would also bedesirable to provide a barrel assembly that thermally separates an outersurface of the barrel assembly from the internal components thereof.

BRIEF DESCRIPTION OF THE INVENTION

The present invention provides a torch, a welding system, and a wirefeed assembly that solves the aforementioned problems. The wire feedassembly includes a motor drivingly connected to at least one roll of apair of rolls. A controller is connected to the motor and is constructedto control the operation thereof. A knob is rotatably connected to thecontroller and facilitates an operator's adjustment of the controller. Acollar is disposed between knob and the controller and is fixedlyconnected to the controller and engaged by the knob to resist movementof the knob and thereby adjustment of the controller.

Therefore, in accordance with one aspect of the present invention, awire feed assembly is disclosed. The wire feed assembly includes a pairof rolls wherein at least one roll is drivingly connected to a motor. Afeed control is connected to the motor and is constructed to control theoperation of the motor. A knob is rotatably connected to the feedcontrol and a collar is disposed therebetween. The collar is fixedlyconnected to the feed control and engaged by the knob to resist movementof the knob.

According to another aspect of the present invention, a torch assemblyhaving a wire feeder attached to a handle is disclosed. The wire feederhas a first roll and a second roll and is constructed to pass aconsumable weld wire through the handle. A motor is attached to thehandle and is constructed to operatively engage at least one of thefirst roll and the second roll. The torch assembly includes amulti-position input device constructed to control the motor. Themulti-position input device includes a stem extending from a bodyattached to the handle. The stem rotatably connected to the body. A dialis attached to the stem and constructed to rotate therewith. A mandrelis attached to the body about the stem and is constructed to resistrotation of the dial.

In accordance with a further aspect of the present invention, a weldingsystem having a power source constructed to generate a power signalsuitable for welding is disclosed. The welding system includes a torchconnected to the power source and a wire feeder constructed to deliver aconsumable weld wire to the torch. A control is connected to the wirefeeder and is constructed to adjust a wire feed speed. An actuator and asleeve are attached to the control. The sleeve is attached to thecontrol between the control and the actuator. A damper is attached tothe sleeve between the sleeve and the actuator.

In accordance with yet another aspect of the present invention, a knobresistance adjustment kit is disclosed. The kit includes a knobconstructed to operatively engage a shaft of a control and a collar. Thecollar has at least one groove formed in an outer surface thereof and anopening formed therethrough. The opening of the collar is constructed tofixedly connect the collar about the shaft of the control. The kitincludes at least one ring having a first surface constructed to snugglyengage the groove and a second surface constructed to snuggly engage theknob thereby restricting rotation of the knob relative to the control.

Various other features and advantages of the present invention will bemade apparent from the following detailed description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate one preferred embodiment presently contemplatedfor carrying out the invention.

In the drawings:

FIG. 1 is a perspective view of a torch assembly attached to awelding-type system according to the present invention.

FIG. 2 is an elevational view of the torch assembly shown in FIG. 1.

FIG. 3 shows the torch assembly shown in FIG. 2 with a portion of thehousing removed therefrom exposing a wire drive assembly of the torchassembly.

FIG. 4 is a plan view of the wire drive assembly shown in FIG. 3 with apair of feed rolls and a lever in a first position.

FIG. 5 is a plan view of the wire drive assembly shown in FIG. 4 withthe feed rolls and lever moved to a second position.

FIG. 6 is cross-sectional view of the wire drive assembly along line 6-6shown in FIG. 4 with the feed rolls and lever in the first position.

FIG. 7 is a cross-sectional view of the wire drive assembly along line7-7 shown in FIG. 5 with the feed rolls and lever in the secondposition.

FIG. 8 is an isometric view of the torch assembly shown in FIG. 2 withthe housing removed therefrom.

FIG. 9 is an elevational view of a barrel assembly of the torch assemblyshown in FIG. 2.

FIG. 10 is an exploded view of the barrel assembly shown in FIG. 9.

FIG. 11 is a cross-sectional view of the barrel assembly shown in FIG.9.

FIG. 12 an isometric view of the feed control assembly removed from thetorch assembly shown in FIG. 2.

FIG. 13 is an exploded view of the feed control assembly shown in FIG.12.

FIG. 14 is a cross-sectional view of the feed control assembly shown inFIG. 12.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows a welding-type system 10 according to the presentinvention. Welding-type system 10 includes a power source 12 tocondition raw power and generate a power signal suitable forwelding-type applications. Power source 12 has a processor 14 within ahousing 16 that monitors the operating condition of welding-type system10. Power source 12 includes a handle 18 attached to housing 16 toeffectuate transportation of power source 12 from one site to another. Acable 20 connects a welding gun or torch assembly 22 to power source 12.Cable 20 communicates weld power, compressed air or weld gas, and aconsumable weld wire to torch assembly 22. Torch assembly 22 includes ahandle portion 24, or torch body, having a trigger 26 thereon and abarrel assembly 28 extending therefrom. Although shown as attached totorch assembly 22, it understood and within the scope of the claims thattrigger 26 be connected to power source 12 or otherwise remotelypositioned relative to torch assembly 22.

Also connected to power source 12 is a work clamp 30 which is designedto connect to a workpiece (not shown) and provide a grounding or returnpath. Connecting work clamp 30 to power source 12 is a cable 32 designedto provide the return path, or grounding path, for the welding powerfrom torch assembly 22 through the workpiece and work clamp 30.Extending from a rear portion 34 of power source 12 is a power cable 36having a plug 38 for connecting power source 12 to either a portablepower supply 40 or a transmission line power receptacle (not shown).Power source 12 includes an ON/OFF switch 42 and may also include anamperage control, a voltage control, selector switches, weld gaspressure regulation controls, indicator lights, and/or the like 44.

To effectuate a welding-type process, barrel assembly 28 of torchassembly 22 is generally pointed to a workpiece connected to work clamp30. Activation of trigger 26 delivers weld power, consumable weld wire,and weld gas to a desired weld area. Maintained activation of trigger 26allows the user to perform extended welding-type processes while movingtorch assembly 22 across the workpiece. The user may adjust the deliveryspeed or feed speed of the consumable weld wire by manipulation of afeed control 46 attached to torch assembly 22. Weld gas or a shieldinggas is supplied to a weld from a pressurized gas source 48 fluidlyconnected to torch assembly 22.

FIG. 2 shows an elevational view of torch assembly 22. Cable 20removeably connects torch assembly 22 to power source 12 andcommunicates welding power, a consumable weld wire, and weld gas to thetorch assembly. Torch assembly 22 includes a first end 50 connected tocable 20 and a second end 52 having barrel assembly 28 connectedthereto. A housing 54 extends about handle portion 24 of torch assembly22 between first end 50 and second end 52. Trigger 26 and a dial 56 offeed control 46 extend through housing 54 and are positioned to allowconvenient, single handed, operator manipulation thereof, respectively.A collar 58 is rotatably attached to housing 54 and engages a torch end61 of barrel assembly 28 and secures the barrel assembly 28 to torchassembly 22. Although barrel assembly 28 is shown as having a relativelystraight configuration, it is understood that the barrel assembly couldhave other orientations such as a slightly bent construction. A cover ordoor 60 is pivotally attached to housing 54 between first and secondends 50, 52 and is positioned on torch assembly 22 generally oppositetrigger 26 and dial 56. Door 60 is rotatable between a closed position62, shown in FIG. 1, and an open position 64, shown in FIG. 2.

As shown in FIG. 2, open position 64 of door 60 exposes a wire driveassembly 66 of torch assembly 22. Wire drive assembly 66 includes afirst feed roll 68 and a second feed roll 70. Wire drive assembly 66delivers a consumable weld wire 72 from power source 12 to torchassembly 22. Wire drive assembly 66 is configured to cooperate with awire drive assembly positioned in power source 12 to deliver consumableweld wire 72 to a weld. Such systems are often referred to as“push-pull” type systems wherein the wire drive assembly positioned inthe power source “pushes” the consumable weld wire to the torch and wiredrive assembly 66 “pulls” the consumable weld wire to the torch. Suchconfigurations provide for efficient transportation of consumable weldwire along extended weld cables. That is, where the distance between thepower source and the torch assembly is too great or the consumable weldwire cannot physically support being only pushed or being only pulled tothe torch, such cooperative wire drive systems provide for greaterversatility of the welding-type system. Alternatively, in thoseapplications where a consumable weld wire can support being only pulledto the torch, or where the distance between the torch and source ofconsumable weld wire is not significant, wire drive assembly 66 canindependently deliver consumable weld wire 72 to a weld.

FIG. 3 shows torch assembly 22 with housing 54 removed therefrom. Asshown in FIG. 3, wire drive assembly 66 includes a motor 74 operativelyconnected to feed control 46 and trigger 26. A gear box 75 drivinglyconnects motor 74 to second feed roll 70. Alternatively, motor 74 couldbe drivingly connected to only first feed roll 68 or both first andsecond feed rolls 68, 70. Understandably, if motor 74 is drivinglyconnected to both first and second feed rolls, the feed rolls rotate indirections generally opposite one another, respectively. Operation ofmotor 74 is controlled by actuation/deactivation of trigger 26 at aspeed determined, in part, by the setting of feed control 46. Motor 74,being driving connected to second feed roll 70, rotates second feed roll70 in a direction necessary to deliver consumable weld wire 72 to aweld.

Wire drive assembly 66 includes a lever 76 pivotally connected thereto.Lever 76 operatively engages an arm 78 pivotally attached to wire driveassembly 66 by a pin 80. First feed roll 68 is rotationally mounted toarm 78. A spring assembly 82 biases arm 78 towards gear box 75 andbiases first feed roll 68 into engagement with consumable weld wire 72when the weld wire is passed through drive assembly 66. As shown in FIG.4, consumable weld wire 72 passes between first feed roll 68 and secondfeed roll 70. Spring assembly 82 compresses consumable weld wire 72between first feed roll 68 and second feed roll 70 such that rotation ofsecond feed roll 70 in the direction indicted by arrow 84 feedsconsumable weld wire 72 through wire drive assembly 66. The movement ofconsumable weld wire 72 past first feed roll 68 rotates first feed roll68 in the direction indicated by arrow 86. Lever 76 includes a handleportion 88 that extends over first feed roll 68 to allow convenientoperator manipulation of lever 76. A boss 90 extends from arm 78 andengages a shoulder 92 of lever 76. Lever 76 is pivotally attached towire drive assembly 66 and is movable in the direction indicated byarrow 94. Movement of lever 76 in direction 94 displaces arm 78, withfirst feed roll 68 rotatably attached thereto, away from second feedroll 70.

Lever 76 and arm 78 are movable between a first position 96, shown inFIG. 4, and a second position 98, shown in FIG. 5. As shown in FIG. 5,lever 76 has been rotated in direction 94 and has disengaged first feedroll 68 from engagement with consumable weld wire 72. Movement of lever76 in direction 94 overcomes the bias of spring assembly 82 and rotatesarm 78 about pin 80. First feed roll 68 is mounted to arm 78 and movesaway from second feed roll 70 attached to gear box 75 as lever 76 ismoved from first position 96 to second position 98. Once rotated tosecond position 98, lever 76 is moved in the direction indicated byarrow 99 and engages a shelf 101 of drive assembly 66 thereby securingfirst feed roll 68 in second position 98. Alternatively, the engagementof shoulder 92 of lever 76 with boss 90 of arm 78 could be constructedto secure arm 78 and first feed roll 68 in second position 98. Suchconstructions provide a torch assembly that maintains second position 98without continuous operator actuation of lever 76. Comparatively, firstposition 96, or a feed position, allows for continuous feeding ofconsumable weld wire 72 through torch assembly 22 while the trigger ofthe torch assembly is activated whereas second position 98 disengagesfirst and second feed rolls 68, 70 from operative engagement withconsumable weld wire 72.

Occasionally, an operator may be required to manually manipulate thepassage of a consumable weld wire to and/or through torch assembly 22.For such instances, such as an initial passage of a weld wire to/throughthe torch, or a threading of the torch, an operator simply manipulateslever 76 to second position 98 shown in FIG. 5. Lever 76 locks in secondposition 98, or a threading position, thereby freeing both of theoperator's hands for manipulation of the consumable weld wire or othercomponents of the weld system. After consumable weld wire 72 has beenpositioned between first feed roll 68 and second feed roll 70, theoperator moves lever 76 to first position 96 thereby allowing springassembly 82 to bias first feed roll 68 into contact with consumable weldwire 72. Spring assembly 82 slightly compresses consumable weld wire 72between first feed roll 68 and second feed roll 70 such that when secondfeed roll 70 is driven by the motor, consumable weld wire 72 is movedthrough torch assembly 22.

As shown in FIG. 6, first position 96 positions consumable weld wire 72snuggly between first feed roll 68 and second feed roll 70. First feedroll 68 is rotatably mounted to arm 78 and second feed roll 70 isrotatably mounted to gear box 75. Second feed roll 70 has a plurality ofdrive grooves 100 formed therein. Drive grooves 100 frictionally engageconsumable weld wire 72 such that driven operation of second feed roll70 by the motor of drive assembly 66 sliplessly moves consumable weldwire 72 through the drive assembly. First feed roll 68 has a groove 102formed therein generally aligned with consumable weld wire 72. Groove102 maintains the position of consumable weld wire 72 between first feedroll 68 and second feed roll 70. Spring assembly 82 includes a spring104 connecting arm 78 to gear box 75. Spring 104 biases first feed roll68 against consumable weld wire 72. Spring assembly 82 includes anadjuster 106 to allow operator manipulation of the loading of spring104. Setting of adjuster 106 determines, in part, the amount ofcompression consumable weld wire 72 is subjected to when positionedbetween first feed roll 68 and second feed roll 70.

Lever 76 is pivotably attached to gear box 75 by a pin 108 at an end 110of lever 76 generally opposite handle portion 88. Shoulder 92 extendsfrom lever 76 between handle portion 88 and end 110. Shoulder 92slidingly engages boss 90 of arm 78. As shown in FIG. 7, rotation oflever 76 about pin 108 displaces shoulder 92 relative to boss 90 of arm78 and secures arm 78 in second position 98. Second position 98disengages first feed roll 68 and second feed roll 70 from operativeengagement with consumable weld wire 72 thereby allowing manualmanipulation of consumable weld wire 72 between feed rolls 68, 70.Maintaining first feed roll 68 in second position 98 frees both of anoperator's hands for threading of consumable weld wire 72 through driveassembly 66. Once an operator has positioned consumable weld wire 72between first feed roll 68 and second feed roll 70, the operator engageshandle portion 88 of lever 76 to return lever 76, arm 78, and first feedroll 68 to first position 96 shown in FIG. 6 thereby drivingly engagingfirst feed roll 68 and second feed roll 70 with consumable weld wire 72.

FIG. 8 shows a perspective view of torch assembly 22 with the housingremoved therefrom. As shown in FIG. 8, cable 20, shown in FIG. 1, hasbeen removed from a first end 116 of torch assembly 22. A liner 118extends from a connection block 120 of torch assembly 22. Liner 118communicates consumable weld wire from a welding device to torchassembly 22. Connection block 120 has a first recess 122 and a secondrecess 124 formed therein. First recess 122 is constructed to connecttorch assembly 22 to weld power and second recess 124 is constructed tofluidly connect torch assembly 22 to a supply of weld gas. A torch weldwire tube 126 and a pair of torch gas tubes 128 connect connection block120 to a second end 130 of torch assembly 22. Weld wire tube 126 isgenerally aligned between liner 118 and a space 132 between first feedroll 68 and second feed roll 70. Weld wire tube 126 guides consumableweld wire 72 through torch assembly 22 to drive assembly 66 andcommunicates weld power through torch assembly 22.

The pair of torch gas tubes 128 also communicate weld power throughtorch assembly 22 and communicate weld gas from connection block 120 tosecond end 130 of torch assembly 22. Torch gas tubes 128 curve aboutdrive assembly 66 and communicate the weld power carried thereon andweld gas carried therein to a barrel end 134 of torch assembly 22.Passing weld gas through both of pair of torch gas tubes 128 providesfor efficient cooling of torch assembly 22 during welding-typeprocesses. Such a construction allows torch assembly 22 to operate atgreater weld powers compared to torch assemblies having only one weldgas passage.

Feed control 46 controls the rate of passage of consumable weld wirethrough torch assembly 22. Feed control 46 includes a first set ofconnectors 136 and a second set of connectors 138. First set ofconnectors 136 communicates to a controller disposed in power source 12via cable 20. The controller disposed in power source 12 communicates adesired power signal as determined by the setting of feed control 46 tomotor 74 of drive assembly 66 via second set of connectors 138.Alternatively, power is communicated to a controller 140 of torchassembly 22 from first set of connectors 136. Second set of connectors138 communicate a variable power signal from controller 140 to motor 74of drive assembly 66. Dial 56 is rotationally connected to controller140 and varies the power provided from controller 140 to motor 74.Operator adjustment of dial 56 adjusts the operating speed of motor 74and thereby adjusts the rotational speed of second feed roll 70.Rotation of dial 56 allows an operator to adjust the speed at whichconsumable weld wire 72 is passed through torch assembly 22 anddelivered to a weld. Positioning feed control 46 on torch assembly 22allows an operator to quickly and efficiently adjust the rate ofdelivery of consumable weld wire 72 to a weld. The construction of feedcontrol 46 is described further with respect to FIGS. 12-14.

FIG. 9 shows barrel assembly 28 attached to barrel end 134 of torchassembly 22. Barrel assembly 28 has a torch end 150 constructed tooperatively engage barrel end 134 of torch assembly 22. Collar 58removeably secures barrel assembly 28 to torch assembly 22. Theoperative engagement between barrel assembly 28 and torch assembly 22fluidly communicates weld gas, consumable weld wire 72, and weld powerfrom torch assembly 22 through barrel assembly 28 and to a work end 152of barrel assembly 28. A guide tube 154 extends from torch end 150 ofbarrel assembly 28 and passes through a barrel frame 156. Barrel frame156 has a plurality of grooves 158, 160, 162, 164 formed therein.Grooves 160, 164 each have a seal 168, 170 positioned therein,respectively. Grooves 160, 164 generally flank groove 162. At least oneorifice 172 is formed in groove 162 and is constructed to pass weld gasradially through barrel frame 156. Seals 168, 170 generally flank groove162 and sealingly connect orifice 172 to a supply of weld gas providedfrom torch assembly 22.

An insulator 174 is positioned about barrel frame 156 and has a flange176 extending therefrom. A sleeve 178 is positioned about frame 156 andhas a first end 180 that generally abuts flange 176 of insulator 174 anda second end 182 that generally abuts a barrel collar 184. Optionally, aplurality of vent holes 186 are formed through sleeve 178 proximatesecond end 182. A nozzle 188 is removably attached to barrel assembly 28at work end 152. Consumable weld wire 72 uninterruptedly passes throughbarrel assembly 28 and exits barrel assembly 28 through nozzle 188.

FIG. 10 shows an exploded view of the components of barrel assembly 28.Guide tube 154 is slidingly received in barrel frame 156. Seals 168, 170have been removed from grooves 160, 164, respectively. Barrel frame 156has a first shoulder 190 near groove 164 and a second shoulder 192 at anend 194 of barrel frame 156. First shoulder 190 of barrel frame 156slidingly receives insulator 174 and generally concentrically alignsinsulator 174 on barrel frame 156 when the insulator is positionedthereon. Insulator 174 has a body 196 having a torch end 198 and abarrel end 200. Flange 176 extends from body 196 between torch end 198and barrel end 200. Barrel end 200 of insulator 174 is constructed toreceive a first spacer 202 thereabout. First end 180 of sleeve 178 issnuggly received about first spacer 202. Alternatively, first spacer 202could be constructed to directly engage barrel frame 156 proximatebarrel end 200 of insulator 174. A second spacer 204 is constructed toslidingly receive barrel frame 156 and have second end 182 of sleeve 178positioned thereabout. Alternatively, sleeve 178 of barrel frame 156could include bosses formed thereon to maintain the separationtherebetween. Barrel collar 184 has an opening 206 formed therethrough.Opening 206 is constructed to allow end 194 of barrel frame 156 to passtherethrough and has a ridge 208 formed thereon. Ridge 208 isconstructed to snuggly engage second end 182 of sleeve. A diffuser 210includes a plurality of gas outlets 212 and operatively engages end 194of barrel frame 156. Diffuser 210 is constructed to axially receivenozzle 188 thereabout.

FIG. 11 shows a cross-sectional view of assembled barrel assembly 28. Asshown in FIG. 11, guide tube 154 extends through barrel assembly 28 todiffuser 210 and is constructed to pass a consumable weld wire thereto.Diffuser 210 includes a threaded recess 214 to removably connect a tip(not shown) thereto. Barrel frame 156 includes a plurality of tubes 216,218, and 220 extending therethrough. Tube 216 is concentricallypositioned about guide tube 154 and electrically isolates guide tube 154from barrel assembly 28. Tube 218, or a headtube, communicateswelding-type power through the barrel assembly to diffuser 210. Tube 220is positioned about tube 218 and isolates tube 218 from the outersurfaces of barrel assembly 28. A gas passage 222 is formed between tube216 and tube 218 and fluidly connects orifice 172 with diffuser 210. Ahead fitting 224 engages tubes 216, 218, and 220 and aligns the tubes tomaintain the separation between tubes 216 and 218 thereby maintaininggas passage 222. Although only one is visible, head fitting 224 includesa plurality of ports 226 radially positioned between head fitting 224and tube 216. Plurality of ports 226 fluidly connect the flow of gas ofgas passage 222 and diffuser 210. Diffuser 210 passes gas provided fromgas passage 222 through gas outlets 212. Passage of gas through gasoutlets 212 floods a nozzle chamber 228 with weld gas for use during awelding process.

Sleeve 178 is snuggly retained between flange 176 of insulator 174 andridge 208 of barrel collar 184. Spacers 202, 204 cooperatively supportends 180, 182 of sleeve 178 and maintain a gap 230 between sleeve 178and barrel frame 156. Gap 230 forms a thermal separation between sleeve178 and barrel assembly 28. That is, the heat associated with barrelframe 156 is prevented from transmitting to sleeve 178, or the outersurface of the barrel assembly. Such a construction provides a torchassembly having a lower barrel assembly operating surface temperature.Accordingly, operator exposure to increased barrel assembly temperaturesis decreased thereby providing a torch assembly that is comfortably usedfor extended periods of welding operation.

Maintaining the comparatively lower operating temperature of barrelassembly 28 can be even further reduced by providing sleeve 178 withoptional vent holes 186. Vent holes 186 extend radially through sleeve178 and fluidly connect gap 230 to atmosphere. Such a constructionprovides that any heat that may accumulate in gap 230 is allowed toescape therefrom. Such a construction reduces the thermal energy that iscontained within the barrel assembly and provides for even greatercooling of barrel assembly 28.

FIG. 12 shows feed control 46 removed from torch assembly 22. Dial 56 isslideably positioned about a stem 232 of controller 140. Controller 140,positionable in power source 12 or torch assembly 22, delivers avariable output power to second set of connectors 138 as determined byfeed control 46. Rotation of stem 232 controls the output powerdelivered from second set of connectors 138. Dial 56 includes aplurality of grooves 234 formed therein. Grooves 234 provide convenientand efficient manipulation of dial 56 by an operator wearing awelding-type glove. Dial 56 has an opening 238 formed therethrough.Opening 238 is constructed to operatively connect dial 56 to stem 232.Opening 238 of dial 56 includes a flat section 240 constructed to engagea flat portion 242 of stem 232. Such engagement rotates stem 232 inresponse to operator rotation of dial 56. Alternatively, dial 56includes a set screw 244 constructed to engage flat portion 242 of stem232. Either construction operatively connects dial 56 to stem 232 ofcontroller 140. Controller 140 includes a shroud 246 that extends from abody 248 of the controller. Shroud 246 isolates dial 56 from an interiorof the torch assembly when feed control 46 is connected thereto. Such aconstruction prevents debris that may accumulate in grooves 234 frombeing transmitted into the torch assembly during rotation of dial 56.

As shown in FIG. 13, body 248 of controller 140 includes a shank portion249 extending therefrom about stem 232. Shank portion 249 includes aplurality of threads 250 formed thereabout. A feed control sleeve, ormandrel, 252 has a threaded opening 254 formed therethrough. Threadedopening 254 is constructed to threadingly connect feed control sleeve252 to body 248 about shank portion 249. Stem 232 extends fromcontroller 140 and rotates relative to body 248 and sleeve 252.Alternatively, rather than the threaded engagement between feed controlsleeve 252 and controller 140, feed control sleeve 252 could be securedto body 248 with a keyed engagement, a set screw connection, or anon-rotatably shaped engagement therebetween. A pair of grooves 256 isformed about an outer surface 258 of sleeve 252. A resistance device260, such as an O-ring, is positioned in each groove 256. Dial 56includes a recess 262 formed therein. Recess 262 is constructed to bepositioned snuggly about sleeve 252 when resistance devices 260 arepositioned in grooves 256.

FIG. 14 shows a cross-sectional view of assembled feed control 46. Asshown, sleeve 252 is threadingly connected to shank portion 249 of body248 of controller 140. Resistance devices 260 are snuggly received ingrooves 256 of sleeve 252. Recess 262 of dial 56 is positioned aboutsleeve 252 and frictionally engages resistance devices 260. Dial 56 isoperatively connected to stem 232 of controller 140 by set screw 244.Such engagement ensures that operator rotation of dial 56 results inrotation of stem 232 and thereby adjusts the output power delivered fromcontroller 140 via second set of connectors 138. The frictionalengagement between resistance devices 260 and dial 56 preventsinadvertent or unintentional rotation of stem 232. Such a constructionprevents any unintentional adjustment of the output power delivered fromfeed control 46. As such, once an operator has determined an optimum ordesired wire feed speed, vibration or movement of the torch assemblywill not change the wire feed speed from the desired speed.Additionally, it is further understood that the degree of resistance tothe rotation of dial can be quickly and efficiently adjusted. That is,by simply changing the size and/or material of resistance devices 260,more or less resistance to movement can be provided to dial 56. It isfurther understood, that although two resistance devices 260 andcorresponding grooves 256 are shown, manipulation of the size/materialof the resistance devices could provide adequate resistance to movementof dial 56 with a single resistance device.

The present invention provides a torch, a welding system, and a wirefeed assembly. The wire feed assembly includes a motor drivinglyconnected to at least one roll of a pair of rolls. A controller isconnected to the motor and is constructed to control the operationthereof. A knob is rotatably connected to the controller and facilitatesan operator's adjustment of the controller. A collar is disposed betweenknob and the controller and is fixedly connected to the controller andengaged by the knob to resist movement of the knob and therebyadjustment of the controller.

Therefore, one embodiment of the present invention includes a wire feedassembly having a pair of rolls wherein at least one roll is drivinglyconnected to a motor. A feed control is connected to the motor and isconstructed to control the operation of the motor. A knob is rotatablyconnected to the feed control and a collar is disposed therebetween. Thecollar is fixedly connected to the feed control and engaged by the knobto resist movement of the knob.

Another embodiment of the present invention includes a torch assemblyhaving a wire feeder attached to a handle. The wire feeder has a firstroll and a second roll and is constructed to pass a consumable weld wirethrough the handle. A motor is attached to the handle and is constructedto operatively engage at least one of the first roll and the secondroll. The torch assembly includes a multi-position input deviceconstructed to control the motor. The multi-position input deviceincludes a stem extending from a body attached to the handle. The stemis rotatably connected to the body. A dial is attached to the stem andconstructed to rotate therewith. A mandrel is attached to the body aboutthe stem and is constructed to resist rotation of the dial.

A further embodiment of the present invention includes a welding systemhaving a power source constructed to generate a power signal suitablefor welding. The welding system includes a torch connected to the powersource and a wire feeder constructed to deliver a consumable weld wireto the torch. A control is connected to the wire feeder and isconstructed to adjust a wire feed speed. An actuator and a sleeve areattached to the control. The sleeve is attached to the control betweenthe control and the actuator. A damper is attached to the sleeve betweenthe sleeve and the actuator.

Yet another embodiment of the present invention includes a knobresistance adjustment kit. The kit includes a knob constructed tooperatively engage a shaft of a control and a collar. The collar has atleast one groove formed in an outer surface thereof and an openingformed therethrough. The opening of the collar is constructed to fixedlyconnect the collar about the shaft of the control. The kit includes atleast one ring having a first surface constructed to snuggly engage thegroove and a second surface constructed to snuggly engage the knobthereby restricting rotation of the knob relative to the control.

The present invention has been described in terms of the preferredembodiment, and it is recognized that equivalents, alternatives, andmodifications, aside from those expressly stated, are possible andwithin the scope of the appending claims.

1. A welding system comprising: a power source constructed to generate apower signal suitable for welding; a torch coupled connected to thepower source for receiving the power signal during a welding operation;a wire feeder constructed to deliver a consumable weld wire to thetorch; a controller disposed in the torch and coupled to the wire feederand constructed to adjust a wire feed speed, wherein the controllerincludes a rotary stem to vary the wire feed speed and an annularportion disposed about the rotary stem; and wherein the rotary stemcomprises a flat side; a dial mounted on the rotary stem of thecontroller at least by an anti-rotation feature, the dial configured tomove in rotation with the rotary stem but not axially during operation;wherein the anti-rotation feature comprises a matching flat side of thedial that engages the flat side of the rotary stem and a set screw thatengages the flat side of the rotary stem; a sleeve disposed between theannular stationary portion of the controller and the dial; and a damperdisposed between the sleeve and the dial, wherein the damper isconfigured to engage the dial and to dampen rotation of the dial and therotary stem during adjustment.
 2. The welding system of claim 1, whereinthe sleeve comprises at least one groove constructed to receive thedamper therein, the damper comprising an O-ring.
 3. The welding systemof claim 1 wherein the dial is slideably positionable about the sleevehaving the damper thereon, the damper being sized to snuggly engage aninterior of the dial.
 4. The welding system of claim 1 wherein the wirefeeder and the controller are mounted in the torch and the wire feederfurther comprises a pair of rolls separable by a lever, the leveraccessible through a housing of the torch and securable in a position tomaintain a separated condition of the pair of rolls.
 5. The weldingsystem of claim 1 further comprising a barrel assembly removablyconnected to the torch, the barrel assembly positioned between a nozzleand a body of the torch and having an insulator constructed tocommunicate a shielding gas and a consumable weld wire to the nozzle anda barrel positioned about the insulator with a space therebetween. 6.The welding system of claim 1 further comprising a plurality ofconductors passing through the torch and constructed to communicate thepower signal to a weld, at least two of the plurality of conductorsconstructed to communicate a shielding gas through the torch to theweld.
 7. The welding system of claim 1, wherein the annular portionincludes a threaded section.
 8. The welding system of claim 7, whereinthe sleeve comprises threads configured to be removably disposed on thethreaded section of the annular portion.